Product Technical Training Freezers (Compressed)

Product Technical Training
Freezers
1
Freezers Overview
• Models
– Model numbers and explanations
• Systems and components
– Main power and distribution
– Temperature control system (refrigeration)
– Communication system (displays and alarms)
– Support systems
• Service tasks
– Configuration
– Maintenance
– Problem-solving
2
Freezers Models Overview
• Helmer offers several models of freezers

• Although the systems for each model may work in a
similar way, the specific parts in those systems may vary
for each model
• Knowing the model number will help you:
– Determine which parts apply for your model so that you can
repair or replace them if necessary
– Understand how those parts are connected so that you can
effectively diagnose and solve problems
3
Freezers Models Model Number
• The model
number
appears on
the product
IPF125-4
specification
label on the
rear of the
freezer, and
on a label
inside the
Number Storage
chamber of doors Configuration
Model Capacity (Plasma
Storage
• The model number has four parts:
iPF125-4 models only)
4
Model explanation
• Model = product series + product group

– The product series describes Number Storage
the range of features.
of doors Configuration
International series have slight
differences for markets Model Capacity (Plasma
outside of USA/Canada Storage
• i.Series Ö full set of features
• Horizon Series Ö base model iPF125-4 models only)
– The product group describes

the application for which it is
typically used
Product series
i.Series Horizon International International
Series i.Series Horizon Series
Product Plasma Storage iPF HPF iHPF HHPF
group
Laboratory iLF HLF
5
Doors, Capacity, and Storage possibilities
Number of doors:
Number Storage
of doors Configuration
1Ö
Model Capacity (Plasma
Storage
iPF125-4 models only)
Capacity: Storage configuration:
-8 Ö -4 Ö
8 drawers 4 shelves,
4 drawers
20 ft3 25 ft3
6
Other features
Monitoring and control system Bezel material and shape
Plastic, curved Metal, rectangular
i.Center Interior surface Storage components

Independent systems • Shelves
White
control and monitor
powder- • Half-shelves
the temperature
Laboratory coated • Drawers
Combined
system both
controls and
monitors the
temperature Stainless
s
Horizon steell
i.Center with
limited features
7
Freezers Models Summary
Product Product Monitoring and Interior/Storage

Group Series Model Control system/Bezel (typical)
Stainless/
i.Series iPF i.Center
8 D or 4S/4D
Stainless/
Horizon Series HPF Horizon
Plasma 8 D or 4S/4D
Storage International Stainless/
iHPF i.Center
i.Series 8 D or 4S/4D
International Stainless/
HHPF Laboratory
Horizon Series 8 D or 4S/4D
Powder-coated/
i.Series iLF i.Center
4 Shelves
Laboratory
Powder-coated/
Horizon Series HLF Laboratory
4 Shelves
8
Freezers Systems and Components
Overview
• The freezer has three main systems:
– Communication system (displays and alarms)
• The freezer also has several support systems
• Components for each system vary by model. Some components are
used in multiple systems.
Main power Communication
and distribution system
Support
Temperature systems
control system
9
Freezers Main power and distribution system
Overview
• The main power and

distribution system distributes
power to other components of
the freezer.
• Components in this system
vary by model. Some
components are used in
multiple systems.
10
Freezers Main power and distribution
system Components
• Main power and Power supply

distribution board (iPF,
components are in HPF, iHPF, iLF)
the electrical box Chart recorder
transformer
Temperature/ Temperature control

defrost transformer transformer
(iPF, HPF, iHPF, iLF) (HHPF, HLF)
Power line filter

Power cord Terminal strips
Main power switch Ground terminal
Circuit breakers strip
11
system Electrical diagram
• Main power is distributed through the “Line” (L1) and “Neutral” (L2)
terminal strips
12
system Electrical diagram
• Some components convert the main

power for use by other components:
– Chart recorder transformer: 12 V ac
– Power supply board: 12 V dc
– Temperature/defrost transformer: 12 V ac
– Temperature control transformer: 12 V ac
13
Freezers Temperature control system
Overview
• The temperature control • Although the control system

system controls the varies by model, the main
temperature of the chamber. components of the cooling
• The temperature control system are about the same.
system is composed of two
sub-systems:
– Cooling (refrigeration) system
– Control system
14
Cooling system (refrigeration)
• Components in the
cooling system Condenser grill
process the refrigerant
to cool the chamber: Condensing unit
Condenser fan
Compressor
Cap
(Capillary)
Evaporator Line drier tube
15
1• EVAPORATOR: The refrigerant enters the
evaporator as a cold low-pressure liquid. The
unit cooler fan blows air from the chamber
across the evaporator. The refrigerant absorbs
2 heat from the air, which converts it to a gas.
5
1
16
2• COMPRESSOR: The refrigerant enters the

compressor as a low-pressure gas. The
compressor compresses the refrigerant, which
2 increases the pressure.
5
1
17
3• CONDENSER: The refrigerant enters the
condenser as a high-pressure gas. The
condenser fan blows air from the room across
the condenser. The refrigerant releases heat to
the air, which converts it to a liquid.
2
5
1
18
4• LINE DRIER to CAP TUBE: The refrigerant
enters the line drier as a liquid. The line drier
absorbs moisture from the refrigerant. The
refrigerant is then forced into the narrow “cap”
(capillary) tube, which increases the pressure.
2
5
1
19
5• CAP TUBE to EVAPORATOR:
The high-pressure liquid refrigerant exits the
narrow cap tube, at which point the pressure
decreases sharply.
2
5
1
20
Control system
• Components in the control system sense the temperature of the

chamber and control when the compressor runs.
• The temperature control probe is located next to the evaporator
inside the chamber in the unit cooler.
• Other components in the control system vary by model
Unit cooler (Evaporator) Temperature control probe

21
Control system – Components
• i.Series models
and the Horizon
Series HPF
model have a
temperature/
defrost controller,
which is located
inside the
electrical box on
the rear of the
freezer
• Horizon Series
models have a Temperature/defrost
monitor/control controller Monitor/control board
board iPF, HPF, iHPF, HHPF, HLF models only
iLF models only
22
Control system – Components
• The control system has

several other components,
depending on the model.
Door switch
all models
Fan delay relay

all models
Compressor relay (50 A) Compressor relay (25 A)

iPF, HPF, iHPF, iLF models HHPF, HLF models
23
Electrical diagram – i.Series and HPF models
24
Electrical diagram – HHPF, HLF models
25
Freezers Communication system
Overview
• The communication system does the following:

– Obtains information from the user
about when information should be
communicated
– Gathers information about the state
of the device
– Evaluates the information and
initiates the appropriate reaction
– Communicates information about
the state of the device to the user
or to other devices.
26
Monitoring system
• The monitoring system is the main factor that determines what types
of information can be obtained, gathered, and communicated.
• Each type of monitoring system has different capabilities.
– Ability to program setpoints for alarms
– Amount of information that can be monitored
• The type of monitoring system varies by model.
Laboratory i.Center Horizon
(used on HHPF (used on iPF, iHPF (limited-feature i.Center
and HLF models) and iLF models) used on HPF models)
27
Monitoring system - Laboratory
(HHPF, HLF)
LCD display shows temperature values
(or “Prob” if the chamber probe When the SET lamp is lit, the
connection is faulty) freezer or alarm setpoints are in
the process of being changed.
Lamps light up if the The display is showing the new
device meets an value.
alarm condition.
When the CONTROL lamp is lit,
Buttons on the the display is showing a
touchpad are used reference temperature, which is
to view and change used to control the temperature
temperature alarm of the chamber.
setpoints.
When the MONITOR lamp is lit,
the display is showing the
current temperature of the
chamber.
This system also controls the temperature of the chamber.
28
Monitoring system – i.Center and Horizon
(iPF, iHPF, iLF) (HPF)
Display shows The display

information changes if
about the current the device is
state of the in an alarm
device. condition
Buttons on the
touchpad are used
to view screens
that have different The Horizon
information. Some monitoring
screens are used system has some
to view and differences but
change alarm works the same
setpoints. way
This system is independent of the temperature control system.

It does NOT control the temperature of the chamber!
29
Monitoring system parts
• Each monitoring system has i.Center and Horizon
one or more circuit boards (iPF, HPF, iHPF, and iLF models)
Laboratory Display
(HHPF and HLF models) board
Monitor/control board
Control
board
30
Temperature probes
• The monitoring system gathers i.Series models

temperature information through (iPF, iHPF, iLF)
temperature probes. The type,
number, and location varies. Condenser
probe
Horizon Series Attaches to
All models with a
models (HPF, condenser
chart recorder
HHPF, HLF) discharge line
Upper chamber Upper chamber

probe probe (self-test)
Chart recorder Lower

probe chamber
Shares bottle probe
with upper
chamber probe
31
Other components for gathering information
• The monitoring system uses

other components to gather
information as well.
All models
Door switch
(used to sense whether
the door is open)
iPF, iHPF, and iLF models

Monitoring system
backup battery holder
and batteries
(low charge or missing
batteries generates an
alarm)
32
Components to communicate information
Alarm buzzer
• The monitoring system uses
several components to
communicate information.
• Depending on the type of
information, communication may
Remote
be visual or audible.
alarm
It may also be sent electronically
interface
to a remote monitoring device.
Display
Lamps
Audible alarm disable key switch Chart recorder

(HHPF and HLF models only) (optional)
33
Alarm comparison
i.Center Horizon Laboratory
Door open The door has been open longer
than X minutes Changeable Changeable 3 minutes
High Temperature read by upper

temperature chamber probe is greater than or
equal to X
Condenser Temperature read by condenser
temperature probe is greater than or equal to X
Low battery Less than 2 hours of power
remaining (Visual only)
No battery Batteries are not installed
AC power Freezer is not receiving
failure AC power Changeable Changeable 0 minutes
Change chart Weekly reminder to change the
paper paper (Visual only)
34
Chart recorder
• The chart recorder continuously records 1 week of temperature data
• Temperature data is gathered from the chart recorder probe
• The backup battery enables the chart recorder to continue working if
the main power to the device is lost
LED Chart paper Motors
Shows the status Pressure-sensitive Rotate the paper
of the chart recorder so no ink is needed and move the stylus
Buttons
Adjust stylus Chart recorder backup
position battery (9 V alkaline)
Stylus Provides 2 hours of
Marks the backup power. If the
temperature line LED is red, the battery
on the paper is low
Time line groove
Chart knob
Used to calibrate
Secures the
the chart paper to
paper to the
the correct time
motor hub
35
Backup power components
• The monitoring system has a

backup power system that
enables it to continue operating
for about 2 hours if the main
power to the freezer fails.
Monitoring system Monitoring system

backup battery backup batteries
(One 9 V (Six 1.5 V
lithium) D-cell alkaline)
36
Electrical diagram – i.Series and HPF models
37
Electrical diagram – HHPF and HLF models
38
Freezers Support systems
Overview
• In addition to the three main systems, the freezer has

several support systems:
– Doors
– Condensation management
– Defrost
39
Doors
• The doors allow access Door handle with lock

to the chamber and Seals the chamber
help to maintain the closed to maintain the
temperature. temperature
• Make sure that the
hinges are free of Upper hinge bracket
debris and lubricated Pivot point for the door
with a general-purpose
grease so that the door Hinge bearing
opens easily. Allows the door
to open and
close easily
Hinge cam
Allows the door to “self-close”
without pushing it closed
Door stop
Lower hinge bracket Limits how far the
Pivot point for the door door can open
40
Condensation management
• When the doors are opened, humid air
enters the chamber
• Condensation from the evaporator flows
through the drain line to the J-tube.
• The drain line heater in the J-tube keeps Drain line
the condensation from freezing on its Water evaporation tray
way to the water evaporation tray.
• The condensate evaporator evaporates
the water as it accumulates in the tray.
The external drain fan The drain line heater
helps control humidity keeps condensation Condensate
in the chamber from freezing evaporator
Condensation that
forms on the strike
plates (where the door
seals) is evaporated
by the mullion heater.
J-tube This heater is located
under the strike plates.
41
Defrost
• The defrost system prevents the ice • If the defrost control

from accumulating on the evaporator system fails, the defrost
so that the cooling (refrigeration) heater limit thermostat
system works efficiently. turns off the defrost
• The defrost control system controls heater.
when the defrost heater runs.
Defrost heater
limit thermostat
Defrost
heater
42
Defrost
• The type of defrost control system varies by model. i.Series and HPF models
– i.Series and HPF models: temperature/defrost
controller
– HHPF and HLF models: defrost controller
• Defrost events are programmed to start
automatically.
– Start times are user-programmable in the
temperature/defrost controller or the defrost controller.
– Recommended 3-4 events per day at roughly equal
intervals during periods of low usage. HHPF and HLF models
– Default setting is 3 events:
• Midnight, 8 AM, 4 PM (16:00)
– Typical duration is 15 to 30 minutes per event.
• For i.Series and HPF models, defrost events can
also be started on demand.
• The defrost process varies by model.
43
Defrost – i.Series and HPF models
Defrost relay
• At the programmed time, the
(located in the
temperature/defrost controller
electrical box)
activates a relay in the controller.
This relay does the following:
– Turns on the defrost heater
– Turns off the compressor and the
unit cooler fan to prevent
distribution of warm air in the
chamber
– (i.Series only) Activates the
defrost relay, which shows the
defrost icon on the i.Center HOME
screen.
• While the defrost heater is on, the Defrost icon
defrost control probe monitors the
temperature in the coldest part of Defrost
the evaporator. control probe
44
• When the defrost control probe senses that

the temperature has reached the defrost
setpoint (about 15 °C), it deactivates the relay
in the controller. When deactivated, this relay
does the following:
– Turns off the defrost heater
– Turns on the compressor and unit cooler fan
– (i.Series only) Deactivates the defrost relay.
The defrost icon is shown on the i.Center
HOME screen for ten more minutes, then is
hidden.
45
46
Defrost – HHPF and HLF models
• At the programmed time, the

Green light =
defrost controller activates a Compressor
relay in the controller. This running
relay does the following:
– Turns on the defrost heater Red light =
– Turns off the compressor and Defrosting
the unit cooler fan to prevent
distribution of warm air in the
chamber
• While the defrost heater is on,
the fan delay/defrost
termination thermostat
monitors the temperature in Fan delay/
defrost
the evaporator.
termination
thermostat
47
• When the temperature at the

thermostat reaches about
15 °C, the thermostat
activates, which in turn
activates a timer relay in the
controller.
• This timer relay does the
following:
– Turns off the defrost heater
– Turns on the compressor after
a brief delay
• After the temperature at the
thermostat reaches about 0 °C,
the thermostat resets, which
then turns on the unit cooler
fan.
48
49
Freezers Systems and Components
Summary
• Main power and distribution system
– Distributes power. Converts voltage for certain
components as needed.
• Temperature control system
– Cooling (refrigeration) system cools the chamber
– Control system controls when the compressor runs
– Door switches control when the unit cooler
(evaporator) fan runs to maintain temperature
• Communication system
– User can set values for alarms
– Visual and audible alarms, plus electronic remote
alarms
• Support systems
– Doors
– Condensation management (evaporator, strike
plates)
– Defrost
50
Freezers Service tasks
Overview
• Service tasks fall into three main categories:
– Configuration
• Customize the device for a particular user or location
– Maintenance
• Maintain the normal operation of the device
– Problem-solving
• Diagnose and solve problems with the device
• The methods for doing these tasks vary by model.
Configuration Maintenance Problem-solving

51
Freezers Configuration
Overview
• Customize the device for a particular user or location

– Moving the freezer and placement requirements
– Installing or moving drawers, shelves, and baskets
– Changing the freezer setpoint (chamber temperature)
– Programming alarm setpoints
– Changing the chart paper
on the chart recorder
– Other tasks
52
Moving and Placement Requirements
• Moving the freezer
– The freezer has locking casters.
– To prevent tipping, be sure that they are all
unlocked before moving the freezer.
• Placement requirements
– Use a grounded outlet
– Avoid direct sunlight, high temperature
sources, heating vents and air conditioning
vents
– Allow 20 cm (8 in) of space above and
8 cm (3 in) behind the freezer
– Make sure the floor is level
– Make sure the ambient (room) temperature
is between 5 °C and 32 °C
– Make sure that the ambient humidity is
80% or less
• Why is the placement important?
53
Placement requirements
• Use a grounded outlet • Make sure the floor is level

– for safety – to allow condensation from the
• Avoid direct sunlight, high unit cooler (evaporator) to drain
properly, and ensure the doors
temperature sources, heating
self-close
vents and air conditioning vents
– to help maintain the chamber
• Make sure the ambient (room)
temperature so the compressor temperature is between 5° C and
does not have to run so often 32 ° C
• Allow 20 cm (8 in) of space above – to allow the maximum amount of
hot air to dissipate from the
and 8 cm (3 in) behind the freezer
condenser grill so the compressor
– to allow hot air to dissipate from does not have to run so often
the condenser grill so the
compressor does not have to run • Make sure that the ambient
so often humidity is 80% or less
– to prevent damage to the
electronics and prevent
condensation from forming in the
chamber
54
Drawers and Shelves
• Installing or moving drawers and shelves
Standards are attached to Drawers have slides.

the walls of the chamber - The outer part of
the slide fits into the
holes on the
standards.
- The inner part of
the slide is attached
to the drawer.
- Each part of the
slide has a wheel
(roller) that prevents
Brackets fit into the holes the drawer from
on the standards. The being pulled out.
shelves engage with the
brackets.
55
Changing the freezer setpoint
• Understanding the freezer setpoint

• Determining the current freezer setpoint
• Changing the setpoint with the temperature controller
(iPF, HPF, iHPF, iLF models)
• Changing the setpoint with the laboratory controller
(HHPF, HLF models)
56
• Understanding the freezer setpoint

– The probe bottle contains a thick liquid
that simulates the plasma that is
stored in the freezer. The liquid
temperature is more stable than the air
temperature.
– The liquid temperature is the freezer
setpoint. This should be -30.0 °C for
plasma storage.
– But the temperature control probe,
which is used to control the
temperature, is not immersed in the
liquid. Instead, it reads the air Upper Temperature
temperature near the evaporator. chamber probe control probe
– So how is the temperature control Used for Used to control
probe reading used to keep the displays and the temperature
plasma at the proper temperature? alarms. of the chamber.
Measures liquid Measures air
temperature. temperature.
57
• Understanding the freezer setpoint i.Series and

(continued) HPF models
– An offset is used to keep the plasma Change the
at the proper temperature. reference
temperature
– The offset is the difference between
in the
the reference temperature and the
temperature
freezer setpoint.
controller
• The reference temperature is the
temperature of the air near the
evaporator (read by the temperature
control probe) HHPF and
• The freezer setpoint is the HLF models
temperature of the plasma (read by Change the
the monitoring system probe). reference
– If the plasma is not at the right temperature
temperature, change the freezer in the
setpoint by changing the reference monitoring/
temperature. control system
58
• Determining the current

freezer setpoint
– Measure the current
temperature of the liquid
– Make sure that the probe
bottle contains at least
120 ml (4 oz) of the 1. Remove the probes from the upper bottle.
simulation solution.
2. Tape the upper chamber probe and
Solution is a 1:1 ratio of
independent thermometer together so their
water to propylene glycol.
ends meet.
– Use an independent
3. Immerse them in the simulation solution so
thermometer for
their ends are immersed about 5 cm (2 in).
measurement.
Thermometer must be 4. Monitor the temperature for about 10
calibrated and traceable minutes to determine an approximate
to appropriate standards. average. The average is the current freezer
setpoint.
59
• Changing the freezer setpoint 1. Press and

with the temperature/defrost hold P to
controller access the
(i.Series and HPF models) parameter
– Change the reference menu
temperature.
– Determine how much to 2. Press the up or down button until
adjust: P03 appears, then press P to show
• If current liquid temperature the current setpoint.
is -29.0 °C
3. Press the up or down button to adjust
• But desired liquid
temperature is -30.0 °C the amount that you determined (for
• Then adjust the reference example, press the down arrow ten times
temperature -1.0 °C to adjust -1.0 °C)
– Make sure that the new 4. Press P to save your changes.
freezer setpoint is within the
operating range 5. Press the up or down arrow until P01
(-15 °C to -30 °C) appears to return to normal operation.
60
• Changing the freezer setpoint with the temperature controller
(HHPF and HLF models)
– Change the reference temperature.
– Determine how much to adjust:
• If current liquid temperature is -29.0 °C
• But desired liquid temperature is -30.0 °C
• Then adjust the reference temperature -1.0 °C
– Make sure that the new freezer setpoint is within the operating range
(-15 °C to -30 °C)
1. Press and release 3. While pressing SET, press the

SEL until the CONTROL appropriate arrow button to adjust
lamp is lit. the amount that you determined
(for example, -1.0° C).
2. Press and hold
SET to show the 4. Release all the buttons to save
current reference your changes.
temperature 5. Press and release SEL until
MONITOR is lit.
61
Programming alarm setpoints
• Programming alarm setpoints

– Using the i.Center monitoring system (iPF, HPF, iHPF, and iLF
models )
– Using the Laboratory controller (HHPF and HLF models)
62
* = Not available
• Using the i.Center monitoring system for HPF models
– Main screen
• Access all other screens
• Press UP or DOWN to highlight
• Press SELECT to select View historical information
• Press HOME to return to the HOME screen about alarms and
operational events*
Start an automatic
temperature alarm test or
view other information*
Change alarm setpoints
Press MAIN to View alarm setpoints

go to MAIN
screen View software versions
and information to
contact Helmer.
View some procedures
for using the freezer*
63
* = Not
• Using the i.Center monitoring system
available for
– View Configuration screen HPF models
• Can view settings but cannot change them from this screen
• No password required to access
Door ajar (open)
alarm setting
Power failure
alarm setting
High temperature
alarm setpoint
Press View
Configuration Condenser
from the MAIN alarm setpoint*
screen
64

– Configuration screen
• Can access screens to change and restore settings.
• Password is required for access.
• The default password is 1234. This can be changed by the user.
• The general user password is 5352. This password will always access the
Configuration screen, even if the user changed the password. This is useful for
resetting a forgotten password.
65

– Set Alarm Setpoint screen
• Accessed through the Configuration screen (password-protected)
• Can change alarm setpoints from this screen
• Press DOWN to highlight and select
• Press INC or DEC to change the value
66
• Using the laboratory controller

– High Temperature setpoint can be changed
– Door open alarm is set at 3 minutes and cannot be changed
– Low Temperature setpoint is not used
3. Press and hold the SET

1. Press and hold both arrow button, then press either of
buttons until the MONITOR light the arrow buttons to change
flashes. the value.
2. Press and release the SEL 4. Release the SET button

button to select the setpoint. to save the new value.
- When the HIGH TEMP and
MONITOR lamps flash, the High 5. Press and hold both arrow
temperature setpoint is selected buttons until the MONITOR
light stops flashing.
67
Changing the chart paper
• The chart paper must be changed after a week’s worth of

temperature data has been recorded.
1. Press the C button 2. Remove 5. Gently lift the stylus

to move the stylus to the chart knob and turn the paper so
the edge of the paper. the correct time lines
up with the groove.
3. Gently lift
the stylus
and remove
the paper.
6. Hold the chart paper to keep it from
4. Press the turning, then reinstall the chart knob.
new paper For proper operation, do NOT adjust
onto the the paper when the knob is tight
motor hub
68
Changing the chart paper
• The i.Center has a visual reminder to change the paper. This

reminder can be enabled or disabled.
• This reminder must be reset so it activates at the proper time.
• You can also see how many days remain until the reminder appears.
The reminder The number of days remaining
appears as an appears here (if enabled).
alarm, similar to the
one shown here.
The setting to
enable, disable,
and reset the
reminder is here
(password
required).
69
Other tasks – Contrast and audible alarms
• Adjusting the display Press the MUTE button

contrast (i.Series and to temporarily silence
HPF models) audible alarms
• Muting audible alarms

• Disabling audible alarms
(HHPF and HLF
models)
Press either of these

buttons to adjust the
display contrast
Turn the key

switch to disable
audible alarms
70
Other tasks – Formats and preferences
Change the
language
Change the
date format
Change how the
alarm sounds
Change the
temperature units
Reset settings to factory defaults

or access advanced settings Enable or disable
(“back door” password required) the temperature
graph (not available
Change the password for HPF models)
71
Other tasks – Languages
• Loading and changing the language used for

displays and alarms
– Two languages can be stored in the i.Center.
– By default, only English is stored and selected
– Language files are part of the software for the
control and display boards
– Additional language files can be loaded from
the flash card
1. Disable all power 4. When the i.Center is 5. Select the

(main and backup) to powered on, the language that
the device software starts loading. you want to
2. Plug the flash card into Do NOT disconnect the load, then
the flash card port power or remove the flash press HOME.
3. Connect to main card until the i.Center has The language
restarted and the SYSTEM file is loaded.
power and enable
OPTIONS screen is 6. Remove the
the battery backup displayed.
flash card.
72
Other tasks – Automatic defrosting
i.Series and HPF models
• Configuring automatic defrosting
– Using the temperature/defrost
controller (i.Series and HPF models)
– Using the defrost controller (HHPF
and HLF models)
HHPF and HLF models
73
• Using the temperature/defrost controller (i.Series and HPF models)

– Viewing and changing the current time
• The time on the temperature/defrost controller should match the time on the
i.Center.
– Viewing and changing the scheduled
defrost times
• Default setting is 3 defrost events:
– Event 1: Midnight (000)
– Event 2: 8 AM (080)
– Event 3: 4 PM (160)
• Start times are programmable in 10-
minute increments
– Third digit is minutes. 2 = 20 minutes
• Recommended 3-4 events per day at
roughly equal intervals during periods of
low usage.
74
• Viewing and changing the current time

1. Press and hold P to access the 4. Press the up or
parameter menu. down button until P35
appears, then press P
2. Press the up or down to show the current
button until P34 appears, minutes setting.
then press P to show the
current hour setting in 5. Press the up or
24-hour format. Midnight down button to adjust
is 00. the minutes, then press
P34 = Hour setting P to save.
3. Press the up or down P35 = Minute setting
6. Press the up or
button to adjust the hour,
down arrow until P01
then press P to save.
appears to return to
normal operation.
75
• Viewing and changing the scheduled defrost times
1. Press the up or 4. Press the up or down
down buttons until P38 button to adjust the setting,
appears, then press P then press P to save.
to show the current 5. Repeat steps 3-5 to view
access code setting. or change other event times.
2. Press the up or P38 = Access code (88)
6. Press the up or down
down button to change P24 = Event 1 (default 000) buttons until P38 appears,
the code setting to 88, P25 = Event 2 (default 080)
P26 = Event 3 (default 160) then press P to show the
then press P to access
the parameter menu. P27 = Event 4 (default OFF) current access code setting.
3. Press the up or down button until 7. Press the up or down button to change
the parameter setting that you want the code setting to 88, then press P to
to view or change appears (P24 to restrict access to the parameter menu.
P27), then press P to show the 8. Press the up or down arrow until P01
current setting. appears to return to normal operation.
76
• Using the defrost controller (HHPF and HLF models)

– Viewing and changing the current time
• Can be set in intervals of 15 minutes
– Viewing and changing the scheduled defrost

times
• Default setting is 3 defrost events:
– Midnight, 8 AM, and 4 PM (16:00)
• Start times are programmable in 15-minute
increments
• Recommended 3-4 events per day at roughly
equal intervals during periods of low usage.
• Default duration for each event is 30 minutes
maximum
– The defrost process will terminate after 30
minutes, even if the fan delay/defrost termination
thermostat has not yet activated.
77
• Viewing and changing the current time

• Turn the time adjustment ring clockwise until the Time adjustment ring
current time indicator shows the correct time
Current time indicator
Noon
(shown set at about
(12 PM)
9:30 AM)
Current time
(hour and minutes
only – no AM/PM)
Midnight
(12 AM)
78
• Viewing and changing the scheduled defrost times

• For each defrost event, flip the two adjacent switches to the ON position.
Each switch set to ON represents 15 minutes of defrost time.
A 30-minute defrost event that

starts at noon (12 PM)
79
Freezers Maintenance
Overview
• Maintain the normal operation of the device

– Testing alarms
– Calibrating displays
– Replacing batteries
– Cleaning the condenser grill
– Lubricating drawer slides
80
Testing high and low temperature alarms
Manual method (All models) Automatic method (i.Series only)
Requires the upper chamber probe When an automatic test program in the
and an independent thermometer to i.Center is selected, a Peltier device
be immersed in a separate container inside the self-test probe is activated
of water (not the probe bottle)
Warm water and ice are added to Current flow through the Peltier device
the water to gradually heat or cool heats or cools the probe until the alarms
the water until the alarms are are activated
activated
The temperature that is displayed on The temperature that is displayed on the
the monitor changes and the alarm monitor does NOT change and the alarm
sounds does NOT sound
81
Testing other alarms
• Power failure
– Change power failure alarm setting to 0
minutes (i.Series and HPF models only.
HHPF and HLF are already set to 0)
– Disconnect from power – verify alarm
activates
• Door Open
– Change Door Ajar (open) alarm setting to 0
minutes (i.Series and HPF models only)
– Open a door – verify alarm activates
(Remember that for HHPF and HLF models,
the setting is 3 minutes)
• No Battery (i.Series models only)
– Remove one of the six D-cell batteries for
the monitoring system (top of the freezer)
– Verify alarm activates
82
Calibrating displays Overview
• i.Center monitoring system

(i.Series and HPF models)
– Calibrating the upper
chamber probe display
– Calibrating the lower
(i.Series models only)
– Calibrating the condenser
probe display (i.Series
models only)
• Laboratory controller (HHPF
and HLF models)
– Calibrating the upper
• Chart recorder
– Calibrating the chart recorder
83
Calibrating displays i.Center
• Calibrating the upper and lower chamber probe displays

– Measure the temperature of the solution in the probe bottle
– Enter and save the new value in the i.Center
Upper probe display
Lower probe display*
* Not available
for HPF models
84

– Measure the temperature of the solution in the probe bottle for the
display that you are calibrating (upper or lower)
• Make sure that the probe bottle contains at least 120 ml (4 oz) of the
simulation solution. If the amount of solution is too low, or the
bottle is empty, you will be calibrating to the wrong temperature!
• Use an independent thermometer for measurement.
1. Remove the probe or probes from the bottle.

2. Tape the chamber probe and independent thermometer
together so their ends meet.
3. Immerse them in the simulation solution so their ends
are immersed about 5 cm (2 in).
4. Monitor the temperature for about 10 minutes to
determine an approximate average. The average will be
the new value.
85

– Enter and save the new value in the i.Center
Select the probe display to be
calibrated: Upper or Lower
(For HPF models, Upper is
selected)
Press DOWN to highlight

Temperature, then press INC or
DEC to change to the new value
Press DOWN to highlight

STORE CALIBRATION,
then press the ENTER
button to save
The Current temperature for the
selected probe changes to the
new value
86
• Calibrating the condenser probe display

– Measure the temperature of the condenser discharge line
• Allow the temperature to stabilize
• Use an independent thermometer for measurement. Thermometer
must be calibrated and traceable to appropriate standards.
87
• Calibrating the condenser probe

– Change the setting in the i.Center
• Screen is only accessible using the “back door” password (5354)
• Process to calibrate is the same as for the other probes
– Process is different for older model freezers
88
Calibrating displays Laboratory controller
• Calibrating the upper chamber probe display

– A monitor offset is used for calibration
• This is a different offset from the one used for temperature control
• Same process as for i.Series models (independent probe, full bottle)
– Change the monitor offset by the adjustment amount
• Determine how much to adjust: If measured is -29.0° C, but display
shows -27.0° C, then you will adjust the monitor offset by -2.0° C
1. Press and hold both arrow 3. While pressing SET, press the
buttons until the appropriate arrow button to change the
MONITOR light flashes. value by the adjustment amount (for
2. Press and release SEL example, -2.0° C)
until only the MONITOR 4. Release the SET button to save your
lamp flashes. The monitor changes.
offset value is displayed. 5. Press and hold both arrow buttons until
the MONITOR lamp stops flashing.
89
Calibrating displays Chart recorder
• Calibrating the chart recorder

• Same process as for chamber probes
– Move the stylus arm to the correct temperature
Press and hold to

increase the
temperature (move When the stylus lines
the stylus outward). up with the correct
temperature on the
Press and hold to paper, release the
decrease the arrow button.
temperature (move
the stylus inward).
90
Other tasks
• Replacing batteries
– Disconnect power to the
freezer for safety
– Replace with fresh non- Batteries are on
chargeable batteries. Do the chart recorder
not reuse any batteries. and the top of the
For models with freezer
i.Centers, replace all six
batteries at the same
time.
• Cleaning the condenser
grill and external drain fan
– Disconnect power to the
freezer for safety
– Clean using a soft brush
and a vacuum cleaner
91
Other tasks
• Lubricating drawer slides

– Make sure the slides are free of ice
and debris
– Lubricate the bearings in the slides
using a lightweight oil
92
Recommended Schedule
• Quarterly • As needed or as determined

– Test the alarms by your organization
– Check calibration of the upper – Check calibration of other
probe display. Calibrate if displays. Calibrate if
necessary necessary
– Check the chart recorder – Check for battery alarms
backup battery. Replace if (i.Series only). Replace the
necessary batteries if necessary
– Check the monitoring system – Check the level of solution in
backup battery or batteries. the probe bottle or bottles.
Replace if necessary Refill if necessary
– Clean the condenser grill and – Clean the exterior, interior,
external drain fan and door gaskets
• Annually
– Check the probe bottle or
bottles for cleanliness. Clean
and refill if necessary
93
Freezers Problem-solving
Overview
• Diagnose and solve problems with the device

– General Operation
– Chamber temperature
– Alarm activation
– Condensation and icing
– Automatic temperature
probe testing (i.Series only)
– Chart recorder
– Viewing historical information
– Using the manuals
94
General operation
• How might you address these problems?

– The i.Center screen is too dark
– The i.Center is not responding – the time is not changing
– Drawers do not slide easily
– The door does not open easily
95
General operation
• If the i.Center screen is too dark

– Lighten the screen by adjusting the
contrast
• If the i.Center is not responding –
the time is not changing
– The electronics might be “locked up”
– Reset the i.Center by disconnecting
the main power and removing a
battery
• If drawers do not slide easily
– Check the slides for ice and debris
and lubricate them if needed
• If the door does not open easily
– Check the hinges for debris and
lubricate them if needed
96
Chamber temperature

– The chamber temperature does not stabilize
– The temperature on the i.Center display is higher or lower than
the actual temperature (iPF, HPF, iHPF, and iLF models)
– “Prob” appears on the lab controller display (HHPF and HLF
models)
• Think about what systems are affected for each of these
problems
97
Chamber temperature
• If the chamber temperature does not stabilize, there is a problem

with the temperature control system.
– What would affect that system mechanically?
• Has the compressor • Is there airflow

seized? through the
condenser?
• Is there enough – Dirty condenser
refrigerant? grill?
– Faulty fan
– Have a motor?
refrigeration
technician • Has the freezer
check
been placed
properly?
– Heat sources
• Is there airflow through the evaporator? – Clearance
– Any obstructions? Ice build-up? – Ambient
– Faulty fan motor? temperature
98
Chamber temperature
• If the chamber temperature does not stabilize, there is a problem

with the temperature control system.
– What would affect that system electrically?
• Are all electrical connections in the circuit secure?
• Are all components receiving power?
• Are any components faulty?
– Temperature control probe
resistance should be 1191 to 2000
99
Chamber temperature
• If the temperature on the i.Center display is higher or lower than the

actual temperature, there is a problem with the communication system.
– What would affect the temperature display in that system?
• Is the i.Center responding, • Is the i.Center

or has it “locked up”? display calibrated?
• Is there enough
solution in the
probe bottles?
• Are all electrical • Is the solution
connections in the frozen?
circuit secure?
• Are all components
receiving power?
• Are any
components faulty?
100
Chamber temperature
• If “Prob” appears on the lab controller display, there is a problem

with the circuit for the chamber temperature probe.
– What would affect the circuit?
• Are all electrical

connections in the
circuit secure?
• Are all components
receiving power?
• Are any
components faulty?
101
Alarm activation

– An alarm is active
– An alarm is not active, but should be
– An alarm is shown, but is not audible
– A High Temperature alarm activates when the door is opened,
then clears shortly after the door is closed
– A Power Failure alarm is active, but the freezer is plugged in.
– The Door Open alarm is activating sporadically
– The No Battery alarm is activating sporadically
– All the alarms are activating sporadically
• Think about the settings and components that are
related to each of the alarms
102
Alarm activation
• If there is a problem with all alarms

– Check components and settings that are common for all alarms
• Was an alarm muted?

(i.Series and HPF models only)
– The remaining mute time
appears on the HOME screen
• Was the alarm volume
changed?
(i.Series and HPF models only)
• Were audible alarms disabled
with the key switch? (HHPF
and HLF models only)
• Are the connections for the
alarm buzzer secure?
• Is the alarm buzzer faulty?
103
Alarm activation
• High Temperature alarm

– Check the components and settings related to the chamber temperature
• Was the setpoint • Is there

changed so that now the enough
alarm activates at a solution in
different temperature? the probe
– A High Temperature bottles?
alarm set too close to
the freezer setpoint
may activate
sporadically whenever • Are any components
the door is opened. faulty?
• Are all electrical connections – A faulty door switch
in the circuit secure? would not stop the unit
cooler fan from
• Are all components receiving drawing in warm air
power? when the door is
opened
104
Alarm activation
• Door Open alarm

– Check the components and settings related to the door
• Is the door
shutting all the
way and
activating the
door switch?
• Was the setpoint changed so
that now the alarm activates at a
different time?
– A setting of 0 minutes would
cause the alarm to activate
immediately when the door is
opened.
105
Alarm activation
• Power Failure alarm • Is the backup • Was the setpoint
– Check the components and battery or changed so that now
settings related to the main batteries the alarm activates
power depleted or at a different time?
missing?
• Is a
component
faulty?
• Is the outlet working?
• Was a circuit breaker tripped?
106
Alarm activation
• No Battery alarm (i.Series only)

– Check the components related to the backup power for the i.Center
• Are batteries installed?

• Were the batteries installed correctly?
• Do the batteries have enough power?
– If the batteries do not have
enough power, they would not be
detected.
107
Alarm activation
• Condenser Temperature alarm (i.Series only)

– Check the components and settings related to the condenser probe and
the condenser
• Are all electrical connections in the circuit secure?
• Is there airflow through the condenser?
– Dirty condenser grill? Faulty fan motor?
• Was the setpoint changed so that now the
alarm activates at a different temperature?
– This setpoint should not be changed.
• Is the display for this probe
calibrated?
– The “back door” password is
required for calibration.
• Is a component faulty?
• Is there enough refrigerant?
– Have a refrigeration technician check
108
Condensation

– There is too much water in the water evaporation tray
– There is too much ice in the chamber
– There is too much water on the doors
– After defrosting, no water flows into the water evaporation tray
• Think about the components that are related to
condensation management
109
Condensation
• Has the freezer been • Is the external fan working?
placed properly? – It should draw air into the
– Level chamber. Hold a piece of
paper against it to check.
– Ambient humidity
maximum of 80% • Is the drain line heater
faulty?
• Is the door shutting
– Is ice is plugging the drain
all the way and
line? • Is the condensate
sealing properly to
keep out humid air? • Is the defrost heater faulty? evaporator hot and
– During the defrost process, drawing the
the current draw should be appropriate current
3.9 to 5.5 A. (0.21 A to 0.35 A)?
• Is the drain line clear of
obstructions and securely
connected?
• Are all electrical
• Is the drain port on the
connections in the
unit cooler damaged?
circuit secure?
110
Condensation
• Starting a defrost event on demand (i.Series and HPF

models only)
– Instead of waiting for the next scheduled defrost time to
troubleshoot problems with the defrost heater, you can defrost
on demand
Press and hold the up

button for about 2
seconds until the defrost
lamp lights. The defrost
event is started.
111
Automatic probe testing
• If the automatic temperature probe test does not work

(i.Series models only), think about:
– Setting for the High Temperature alarm
– The self-test probe and related components
• Is the alarm setpoint set

significantly higher than the default
value (-20.0 °C)?
– If the alarm setpoint is very high,
the Peltier device will take longer to
heat.
• Are all electrical connections in the
circuit secure?
– If the self-test probe is not receiving
power, the Peltier device cannot
heat or cool the probe.
• Is a component faulty?
112
Chart recorder

– The chart paper is not rotating
– The stylus is at the edge of the paper and will not move
– The stylus moves beyond the outer or inner edge of the paper
– The stylus is marking at the wrong time
– The stylus is marking at the wrong temperature
– The marking is more erratic, fuzzy, or saw-toothed than normal
113
Chart recorder
• If the paper is not rotating, the problem is related to the paper motor
• Is the knob that hold • Are the connections between • Is the chart
the paper to the motor the paper motor and the recorder receiving
hub fully tightened? circuit board secure? power?
• Are the mechanics of the chart recorder working properly?

– Run a test pattern to verify
– If the mechanics are working, restart the chart recorder. Power
114
Chart recorder
• Running a test pattern

– This process tests the mechanics (motors and stylus movement) by
marking a test pattern on the paper
• Press and hold • The stylus should

the C button and mark a test
right arrow button pattern as the
together until the paper makes one
LED turns off. full revolution.
• Restarting the chart recorder

– This process may solve software or electronics problems
• Gently lift the paper to expose the reset button.

• With a narrow tool (such as a paper clip), press and
release the reset button. The LED will flash as the
chart recorder initializes.
115
Chart recorder
• If the stylus is at the edge of the paper and will not move,
there is a problem with either the mechanics of the chart
recorder or with how the temperature is being sensed.
– One possible cause is that the temperature range is set
incorrectly.
• There is a setting that specifies the temperature range of the device
on which the chart recorder is installed.
• If this setting is set to the wrong device, the probe will not sense the
temperature correctly, and the chart recorder will not mark the
temperature correctly.
– Another possible cause is that there is a problem with the probe
circuit.
• There is a mode called “probe simulation” mode, which is useful for
isolating the problem in the probe circuit.
• However, if the chart recorder is not returned to normal mode, the
chart recorder will not sense and mark the temperature correctly.
116
Chart recorder
• Viewing or changing the temperature range setting

To view the setting: To change the setting:
• Press and hold the C button until the stylus 1. View the setting
starts to move to the left. The LED will flash 2. Press and hold the left arrow
green to indicate the temperature range. button until the LED flashes red
– 1 (single flash) = 0 to 35 °C (Incubators) to indicate the selected range.
– 2 (double flash) = -5 to 20 °C (Refrigerators) 3. While pressing the left arrow
– 3 (triple flash) = -50 to 0 °C (Freezers) button, press and release the
right arrow button to change to
the correct range.
4. Save the change by releasing
all the buttons. The LED will
flash green.
When you are done viewing or changing the
setting, return to normal operating mode by
pressing and holding the C button until the stylus
starts to move to the right.
117
Chart recorder
• Testing the probe circuit
To put the chart recorder in “probe simulation” mode:

– Disconnect the probe from the circuit board
– Move the JP1 jumper so that it connects both pins.
To isolate where the
problem is, check the LED:
– Constant: the problem is with the probe
or the connection to the circuit board.
– Flashing: the problem is with the circuit
board.
When you are done testing the circuit,
return to normal operating mode.
– Move the jumper so it does not
connect the pins
Power
– Reconnect the probe
118
Chart recorder
• If the stylus moves beyond the • If the stylus is marking at the
outer or inner edge of the paper, wrong temperature,
– Is there a problem with the probe – Is the chart recorder calibrated?
circuit? – Is there a problem with the probe
– Was the chart recorder circuit?
accidentally left in “probe – Was the chart recorder
simulation” mode? accidentally left in “probe
– Is the temperature range set simulation” mode?
correctly? – Is the temperature range set
• If the stylus is marking at the correctly?
wrong time, • If the temperature marking is more
– When the paper was changed, erratic or “saw toothed” than
was the current time aligned with normal, what might cause this
the groove? problem?
– Was the paper adjusted after the – Hint: This type of is marking is due
knob was tightened? This will to temperature fluctuations. What
cause the motor to lag and mark temperature should the probe be
at the wrong time. reading?
119
Viewing historical information
• Event Log and Defrost Log screens (i.Series only)

– The event log contains information about the most recent 50 alarm events.
• For each alarm, information is recorded in the log when the alarm was
started (S) and reset (R).
– The defrost log contains information about the previous 50 defrost events.
• For each defrost event, information is recorded in the log when the event
started (S) and ended (E)
– These logs may contain information useful for troubleshooting
120
• Event Log and Event Log Detail screens (i.Series only)

– Additional information about each alarm event is available on the Event
Log Detail screen
For the highlighted DR = Door Open alarm
event, press HI = High temperature alarm
SELECT to see CO = Condenser temperature alarm
NB = No battery alarm
more information.
AC = Main (AC) power failure alarm
If the whole event is
highlighted, the event is
for an automatic
temperature probe test.
121
• Defrost Log and Defrost Log Detail screens (i.Series only)

– Additional information about each defrost event is available on the Defrost
Log Detail screen
For the highlighted
event, press
SELECT to see
more information.
122
• Temperature graph (i.Series only) and chart recorder

– Continuous temperature data is available from the temperature graph
and the chart recorder.
123
Using the manuals
• Each device typically has two manuals, each of

which provides different information
– Operation Manual
• Written for users (operators)
• Installation, configuration, and usage information
• Cleaning, maintenance and recommended schedule
• Device specifications
• Basic user-level troubleshooting information.
– Service Manual
• Written for service technicians
• Intended for use with the Operation Manual
• Advanced troubleshooting and maintenance
information
• Repair information
• Part numbers and electrical schematics
124
Freezers Service tasks
Summary
Configuration
– Moving the freezer and placement requirements
– Installing or moving drawers and shelves
– Changing the freezer setpoint
– Programming alarm setpoints
– Changing the chart paper on the chart recorder
– Other tasks (languages, units, temperature graph, defrost)
Maintenance Problem-solving
– Testing alarms – General Operation
– Calibrating displays – Chamber temperature
– Replacing batteries – Alarm activation
– Cleaning the – Condensation and icing
condenser grill and – Automatic temperature
external drain fan probe testing
– Lubricating drawer slides – Chart recorder
– Viewing historical information
– Using the manuals
125
Freezers Summary
• Models
– Product series: i.Series / Horizon
– Product group: Plasma Storage / Laboratory
– Monitoring system, Number of doors, Capacity, Interior finish
• Systems and components
– Communication system
(displays and alarms)
– Support systems
• Service tasks
– Configuration
– Maintenance
– Problem-solving
126
Freezer Practical
Examination
• Examine all Temperature • Examine all monitoring and

control components support system components
– Condensing unit – Similar to refrigerators, focus
– Evaporator on:
– Probes • Defrost controls
• Fan delays
– Temp Controllers
• Defrost log
– Fan delay relay
• Strike plate heater
– Door switch • Door gaskets
• Examine all Power distribution
components
– Power switch
– Breakers
– controllers
127
Freezer Practical
Procedures
• all Temperature control

components
– Verify program values
– Adjust temperatures
– Adjust defrost times
– Remove and replace
• Fan motors
• Controller
• probes
• Etc…
128

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Product Technical Training

• Helmer offers several models of freezers

• Model = product series + product group

– The product group describes

iPF125-4 models only)

Capacity: Storage configuration:

Plastic, curved Metal, rectangular

i.Center Interior surface Storage components

Product Product Monitoring and Interior/Storage

• The main power and

• Main power and Power supply

Temperature/ Temperature control

Power line filter

• Some components convert the main

• The temperature control • Although the control system

2• COMPRESSOR: The refrigerant enters the

• Components in the control system sense the temperature of the

Unit cooler (Evaporator) Temperature control probe

• The control system has

Fan delay relay

Compressor relay (50 A) Compressor relay (25 A)

• The communication system does the following:

Display shows The display

This system is independent of the temperature control system.

• The monitoring system gathers i.Series models

Upper chamber Upper chamber

Chart recorder Lower

• The monitoring system uses

iPF, iHPF, and iLF models

Audible alarm disable key switch Chart recorder

High Temperature read by upper   

• The monitoring system has a

Monitoring system Monitoring system

• In addition to the three main systems, the freezer has

• The doors allow access Door handle with lock

• The defrost system prevents the ice • If the defrost control

• When the defrost control probe senses that

• At the programmed time, the

• When the temperature at the

Configuration Maintenance Problem-solving

• Customize the device for a particular user or location

• Use a grounded outlet • Make sure the floor is level

• Installing or moving drawers and shelves

Standards are attached to Drawers have slides.

• Understanding the freezer setpoint

• Understanding the freezer setpoint

• Understanding the freezer setpoint i.Series and

• Determining the current

• Changing the freezer setpoint 1. Press and

1. Press and release 3. While pressing SET, press the

• Programming alarm setpoints

Press MAIN to View alarm setpoints

• Using the i.Center monitoring system

• Using the i.Center monitoring system

• Using the laboratory controller

3. Press and hold the SET

2. Press and release the SEL 4. Release the SET button

• The chart paper must be changed after a week’s worth of

1. Press the C button 2. Remove 5. Gently lift the stylus

• The i.Center has a visual reminder to change the paper. This

• Adjusting the display Press the MUTE button

• Muting audible alarms

High Temperature read by upper